Modular Fluid End Housing for High-Pressure Pump Wear Control
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Solution Overview
Problem
Conventional fluid ends used in hydraulic fracturing operations are prone to structural failure due to high operational pressures, leading to fluid leakage and erosion, which results in frequent replacements and increased operational costs.
Innovation Solution
A high pressure pump configuration featuring a fluid end assembly with a multi-piece housing design and stay rods, allowing for modular replacement of sections to extend the pump's operational life and reduce maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid ends are used in hydraulic fracturing operations, then high pressure fluid delivery is achieved, but structural failure occurs due to high operational pressures leading to erosion and frequent replacements
Solution Approach 1:
The housing is divided into multiple separable sections (first housing section, second housing section, third housing section) that can be independently removed and replaced. This segmentation allows worn sections to be replaced without replacing the entire housing, extending operational lifespan while maintaining structural reliability under high pressure.
Solution Approach 2:
The modular housing sections can be discarded when worn and replaced with fresh sections. The stay rods and other components remain in place and are recovered for continued use, reducing replacement frequency and costs while maintaining the structural integrity needed for high pressure operation.
2Ease of repair
If modular housing sections are used, then replacement frequency is reduced and maintenance costs decrease, but device complexity increases due to multiple housing sections and stay rods
Solution Approach 1:
The housing is segmented into standardized sections that can be independently accessed and replaced. This segmentation simplifies maintenance by allowing technicians to replace only the worn section rather than the entire housing, improving ease of repair despite the increased number of components.
Solution Approach 2:
The stay rods serve multiple functions: they connect housing sections together, provide structural support, and act as alignment features during assembly. This multi-functionality reduces the need for additional specialized components, offsetting the complexity increase from modular design.
Data Source
AI summary
A high pressure pump. The pump comprises a fluid end assembly supported on a power end assembly. The power end assembly is modular and held together by a first set of stay rods. The fluid end assembly comprises a plurality of fluid end sections positioned in a side-by-side relationship. Each fluid end section comprises a housing made of multiple-piece construction. One or more pieces of the housing are configured to having a second set of stay rods attached thereto. The second set of stay rods interconnect the fluid end assembly and a power end assembly and are vertically offset from the first set of stay rods.